GRACE FOUNDATION SOLUTIONS · CASE STUDY
Project Summary
Client
Pacific Process Limited (on behalf of Open Country Dairy)
Location
Pukekohe, Auckland
Application
Industrial silo base void filling and load support
Technology
Grace Foundation Solutions structural resin injection
Scope
5 stainless steel silo bases
Load Rating
55,000+ kg liquid weight per vessel
Duration
10 working days
Outcome
100% void fill confirmed. All 5 bases completed on schedule.
About This Project
When Pacific Process Limited needed the bases of five large stainless steel silos filled and load-rated for Open Country Dairy, they needed a material that could flow into complex voids, cure to structural strength, and support over 55,000 kg of liquid weight per vessel. Grace Foundation Solutions delivered a precision resin void-fill solution — completing all five silo bases in 10 working days with zero disruption to the wider site.
The Challenge
Pacific Process Limited had fabricated and installed five large stainless steel silos for Open Country Dairy — a major New Zealand dairy producer — at their Pukekohe facility. Each silo was designed to hold tens of thousands of litres of liquid dairy product, placing an enormous structural load on each base.
The silo bases contained internal voids that needed to be completely filled with a construction-grade material capable of:
- Flowing into and completely filling complex internal void geometries
- Curing to a structural strength sufficient to support 55,000+ kg of liquid load
- Being delivered through limited access points — three 30mm diameter holes per base
- Being completed within a tight construction programme alongside other trades
Standard fill materials such as concrete grout were not suitable — access constraints made traditional pouring impossible, and the risk of unfilled voids beneath a load of this magnitude was unacceptable.
Site Investigation
Richard Ushaw, Grace Foundation Solutions’s lead specialist, visited the Pukekohe site to conduct a thorough inspection of all five silo bases prior to works commencing. The inspection assessed:
- The internal geometry of each base and the nature of the voids to be filled
- The location, diameter, and usability of the three existing 30mm access points on each base
- The structural load requirements and cured-strength specification needed for each base
- The site logistics — working alongside other active trades within a live construction programme
Following the inspection, it was clear that Grace Foundation Solutions’ structural resin void-fill system was the ideal solution. The resin’s ability to flow freely into complex cavities, expand to fill all available space, and cure to a high compressive strength made it uniquely suited to this application — something no conventional fill material could achieve through a 30mm access point.
The Solution — Grace Foundation Solutions Structural Resin Void Fill
Grace Foundation Solutions used 5-metre aluminium injection tubes, inserted through each of the three 30mm access points on every silo base. The extended tube length was critical — it allowed the team to reach the full depth of each base and ensure the resin was placed precisely where it was needed.
The injection sequence followed a deliberate three-stage approach:
Stage 1
Rear fill — injection tubes were positioned at the back of each base first, ensuring resin flowed forward and upward rather than short-circuiting to the access points.
Stage 2
Mid-section fill — once the rear void was confirmed full, injection was moved to the mid-section. Three separate layers were built up progressively to ensure complete fill and structural continuity.
Stage 3
Front fill — the final layer brought the fill to the front of the base, completing the void encapsulation.
Real-Time Quality Verification
Throughout each injection, a second Grace Foundation Solutions team member used a Hilti keyhole camera — inserted through the access points — to visually monitor the resin behaviour in real time. This allowed the team to:
- Confirm the resin was flowing as modelled and filling the void from back to front
- Identify any areas requiring additional injection volume
- Provide documented visual evidence of complete fill for the client’s records
This live verification approach — combining injection expertise with real-time visual confirmation — is characteristic of how Grace Foundation Solutions operates on technically demanding projects.
Site Footprint
The entire operation ran from the Grace Foundation Solutions 3-tonne van. No heavy plant, no large equipment compounds, no disruption to the surrounding site. Other trades were able to continue working unimpeded throughout the 10-day programme — a significant advantage on a busy construction site with a tight completion schedule.
It is worth noting that during the project, resin drums required warming to maintain optimal viscosity for injection — the Grace Foundation Solutions team used drum warmers to manage this, ensuring consistent product performance despite the conditions. This kind of proactive problem-solving on site is what allowed the project to stay on schedule despite variables outside anyone’s control.
The Result
All five silo bases were completed within the 10-day programme. Void fill was confirmed as complete across all bases via the Hilti keyhole camera inspections conducted during injection. Pacific Process Limited were able to hand over the finished silos to Open Country Dairy fully confident in the structural integrity of each base under full liquid load.
Project outcomes at a glance
- 5 of 5 silo bases completed — 100% project delivery
- Full void fill confirmed via real-time keyhole camera inspection
- Structural load rating of 55,000+ kg per vessel achieved
- Completed on schedule within a 10-working-day programme
- Minimal site footprint — single 3-tonne van, no disruption to other trades
- 5-star review received from Pacific Process Limited
Why Grace Foundation Solutions for Industrial Void Fill?
This project demonstrates that Grace Foundation Solutions’ resin injection technology is not limited to residential foundation movement. The same precision, the same material properties, and the same engineering-led approach that stabilises Auckland homes is equally applicable to complex commercial and industrial challenges.
Where access is restricted, load requirements are high, and programme constraints are tight — Grace Foundation Solutions delivers.
“Had Richard assist us with a silo installation recently. Very happy with the works. Tight timeframe, and despite shipping delays (outside of anyone’s control), the team at Grace Foundations utilised drum warmers to speed up the process and ensure we hit our target. Good communication throughout. Would recommend.”
Daniel Smith
Local Guide · Pacific Process Limited
Grace Foundation Solutions is suited to:
- Confined access void filling
- High-load structural base support
- Complex commercial & industrial applications
- Projects with tight on-site programmes
- Infrastructure and ground stabilisation
What sets us apart:
- Engineering-led approach to every project
- Real-time quality verification on site
- Minimal site footprint — no heavy plant
- Proven performance under extreme load
- Part of the Grace Foundation Group
Have a commercial or industrial void-fill challenge?
Grace Foundation Solutions works with engineers, contractors, and project managers across Auckland on complex stabilisation and void-fill challenges. If you have a project that requires precision injection into a confined or difficult access environment, we’d like to hear from you.